Manufacturing materiel supply chain disruption management system

ABSTRACT

A manufacturing materiel management system. The system includes a product inventory monitor including at least one processor having a memory and a communications link, and at least one of a minimum-maximum item matrix and an item supplier dependency matrix. The system includes a manufacturing line item sensor network coupled to the product inventory monitor and configured to monitor in real-time inventory levels of a plurality of components, sub-assemblies, and assemblies in the product inventory used for a manufacturing line for manufacturing an object. The system includes a disruption pattern detector in communication with the manufacturing line item sensor network, and configured to detect normal and abnormal inventory turns, and to generate therefrom normal and disruption patterns. The system includes a resource allocator configured to monitor the normal and disruption patterns and to allocate resources to different projects when a disrupted pattern occurs.

BACKGROUND INFORMATION 1. Field

The present disclosure relates to a learning disruption event handler.More particular, the present disclosure relates to a method ofmanufacturing including adjusting resources in response to a majordisruption event to a manufacturing endeavor.

2. Background

Current inventory management systems do not take into accountrelationships of inventory dependencies and cascading challenges thatoccur when disruption events happen. For example, for an aircraftmanufacturer, when a fuselage being transported to a manufacturingfacility is damaged by a third party, the disruptive effect ripplesthrough the entire business enterprise. Examples of such disruptioneffects include, but are not limited to, idling of personnel assigned towork on that fuselage, disruption of the production schedule of otheraircraft, disruption of the overall manufacturing line, incorrectphysical location of parts as other fuselages made for differentcustomers are advanced in the manufacturing line, disruption of othernon-aircraft aspects of the business as a result of disruption of themanufacturing time table for the aircraft, inventory levels of someparts may be excessive while inventory levels of other parts may bestarved. Usually, many other major disruptions to the enterprise occuras a result of a loss of a single major assembly, such as the examplefuselage. Other vendors may also be disrupted, resulting in cascadingdependent inventory management issues.

SUMMARY

The illustrative embodiments provide for a manufacturing materielmanagement system. The system includes a product inventory monitorincluding at least one processor having a memory and a communicationslink, and at least one of a minimum-maximum item matrix and an itemsupplier dependency matrix. The system includes a manufacturing lineitem sensor network coupled to the product inventory monitor andconfigured to monitor in real-time inventory levels of a plurality ofcomponents, sub-assemblies, and assemblies in the product inventory usedfor a manufacturing line for manufacturing an object. The systemincludes a disruption pattern detector in communication with themanufacturing line item sensor network, and configured to detect normaland abnormal inventory turns, and to generate therefrom normal anddisruption patterns. The system includes a resource allocator incommunication with the product inventory monitor, the manufacturing lineitem sensor network, and the disruption pattern detector, and configuredto monitor the normal and disruption patterns and to allocate resourcesto different projects when a disrupted pattern occurs.

The illustrative embodiments also provide for a manufacturing materielmanagement system. The manufacturing materiel management system includesa manufacturing assembly line, including equipment usable to manufacturean object comprising a plurality of parts, including a part. Themanufacturing materiel management system also includes a computercomprising a processor, an input device, and a non-transitory computerreadable medium in communication with the processor, the non-transitorycomputer readable medium storing computer usable program code executableby the processor to perform functions. These functions include tomonitor the input device for input that indicates a disruption eventdefined as an event in which manufacture of the object is disrupted as aresult of loss of a resource or the part. These functions also includeto, responsive to receiving the input, calculate another project whichmay continue. These functions also include to, responsive to receivingthe input, calculate remaining resources which may be allocated to theanother project. These functions also include to generate a resourcere-allocation plan which defines how remaining resources are to bere-allocated to the another project. The manufacturing materielmanagement system also includes a communication system in communicationwith the computer and configured to communicate the re-allocation planto a manager of the manufacturing assembly line.

The illustrative embodiments also provide for a method of manufacturing.The method includes operating a manufacturing assembly line, includingusing equipment to manufacture an object comprising a plurality ofparts, including a part. The method also includes monitoring, by acomputer, an input device in communication with the computer for inputthat indicates a disruption event defined as an event in whichmanufacture of the object is disrupted as a result of loss of a resourceor the part. The method also includes responsive to receiving the input,calculating, by the computer, another project which may continue. Themethod also includes, responsive to receiving the input, calculating, bythe computer, remaining resources which may be allocated to the anotherproject. The method also includes generating, by the computer, aresource re-allocation plan which defines how remaining resources are tobe re-allocated to the another project. The method also includescommunicating, using a communication system connected to the computer,the re-allocation plan to a manager of the manufacturing assembly line.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a diagram illustrating a manufacturing materiel managementsystem, in accordance with an illustrative embodiment;

FIG. 2 is a diagram illustrating an operation of a disruptioncontroller, in accordance with an illustrative embodiment;

FIG. 3 is a diagram illustrating an example of a production line, inaccordance with an illustrative embodiment;

FIG. 4 is a block diagram illustrating a manufacturing materielmanagement system, in accordance with an illustrative embodiment;

FIG. 5 is a block diagram illustrating another manufacturing materielmanagement system, in accordance with an illustrative embodiment;

FIG. 6 is a flowchart of a method for manufacturing, in accordance withan illustrative embodiment; and

FIG. 7 illustrates a data processing system, in accordance with anillustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account thatdisruptions in a manufacturing environment may result in disruptive,enterprise-wide ripple effects. Due to the realities of managing thesupply chain, delays in inventory ordering, shipping, and delivery canoccur. Accordingly, momentum in the supply chain may manifest,especially during disruptions. When large scale interruptions occur,people must notice and think about what potentially could be happeningand how to adjust supplier levels. Thus, the illustrative embodimentsalso recognize and take into effect that current inventory andmanufacturing management systems cannot handle disruption events andtheir ripple effects.

As used herein, the term “disruption event” is defined as an event inwhich manufacture of an object is disrupted or delayed as a result ofloss of a resource, loss of a part, a shortage of human resources (suchas manufacturing personnel), or other non-supply chain disruptiveevents. As used herein, the term “major disruption” refers to adisruption in a manufacturing environment which affects at least twoother, different and significant aspects of the manufacturing endeavor,and further includes at least one dependent effect caused by thedisruption.

As used herein, the term “human resource” disruption refers todisruptions caused by a lack of desirable human resources as a result ofany cause. For example, a strike may cause an insufficient number ofpersonnel to be available to construct an aircraft. In another example,insufficient qualified personnel may be available for hire, which causesan insufficient number of personnel to be available to completemanufacturing of an object. Other examples are possible.

As used herein, the term “non-supply chain” disruption refers todisruptions caused by events which are not directly tied to the supplychain used in supporting a manufacturing enterprise. As used herein, theterm “supply chain” is defined as a system of materiel, components, orparts involved in manufacturing a product from beginning to end of themanufacturing process.

For example, a major disruption in an aircraft manufacturing environmentmay be the loss of a fuselage to be used to build an aircraft when theloss is caused by a third party. At least two other different andsignificant aspects of the manufacturing endeavor occur, such asdisruption of the manufacturing line and idleness of personnel who wouldhave worked on that fuselage had it been delivered. Additionally, atleast one dependent effect would occur, such as disruptions in bothinventory levels and the physical location of inventory items used inmanufacturing. Usually, disruptions also ripple to vendors and otheraspects of the company managing the manufacturing endeavor. Examples ofevents that my cause major disruptions include long term powerdisruption, supply delivery accidents caused by third parties, stormdisruptions, and potentially many other events.

The illustrative embodiments provide for a learning disruption eventhandler. The learning disruption event handler acts as a learninginventory management supervisory system that monitors both manufacturingactivities and inventory levels and then learns to proactivelyreallocate resources based on contextual awareness. The illustrativeembodiments described herein take into account relationships ofinventory dependencies and cascading challenges that occur whendisruption events transpire. The illustrative embodiments contemplateusing and building upon systems such as those described in our earlierwork described in U.S. Pat. No. 7,769,643 and U.S. Pat. No. 8,700,499.

The illustrative embodiments may manage the inventory of an entireecosystem of a manufacturing environment, including both the enterpriseand its vendors. Managing the inventory level of the entire ecosystemresults in reduced inventory and supply chain anticipation. By usingpattern-based triggers, the illustrative embodiments automaticallyanticipate what potentially could be happening and how to adjustsupplier levels.

The illustrative embodiments provide rule-based artificial intelligencesystems which leverage big data analytics. For example, the illustrativeembodiments may look at systemic effects of disruption across supplychain. The illustrative embodiments provide for “Internet of Things”sensing, including a system of systems approach to determine eventparameters, impact, and scope. The illustrative embodiments provide formachine learning for disruption patterns and outcomes. The illustrativeembodiments provide for a supplier dependency table which describes howa disruption will affect supplier schedules. The illustrativeembodiments provide for a disruption pattern detector. The illustrativeembodiments provide for an alert reporting system which notifies anexternal supply chain of disruption and anticipated duration. Theillustrative embodiments may recommend alternative internal tasksdepending on duration. The illustrative embodiments may recommendmaintenance to be performed in lieu of manufacturing as a result of thedisruption event. The illustrative embodiments may initiate training orcertification opportunities to capitalize on personnel time which wouldotherwise be idle. The illustrative embodiments may proactively beginreallocating resources for optimization when a disruption event occurs.The illustrative embodiments may update and modify a manufacturing workflow system that manages parts, plans, tools, tasks, people, andassociated drawings according to new resource requirements andallocation.

Thus, the illustrative embodiments may provide for a manufacturingmateriel management system. The manufacturing materiel management systemmay include a product inventory monitor including at least one processorhaving a memory and a communications link. The manufacturing materielmanagement system may also include an at least one of a minimum-maximumitem matrix and an item supplier dependency matrix. The manufacturingmateriel management system may also include a manufacturing line itemsensor network coupled to the product inventory monitor and configuredto monitor in real-time inventory levels of a plurality of components,sub-assemblies, and assemblies in the product inventory. Themanufacturing materiel management system may also include a disruptionpattern detector in communication with the manufacturing line itemsensor network, and configured to detect normal and abnormal inventoryturns, and to generate therefrom normal and disruption patterns; and aresource allocator in communication with the product inventory monitor,the manufacturing line item sensor network, and the disruption patterndetector, and configured to monitor the normal and disruption patterns.The illustrative embodiments may then generate: (a) one or more of lineresource plan allocation and reallocation parameter, and (b) if adisruption pattern is detected, at least one priority disruptionparameter that defines an adjusted minimum-maximum item matrix and anadjustment alert.

The illustrative embodiments may confer a technical advantage and allowan enterprise to monitor its manufacturing progress through the buildcycle with more confidence. The illustrative embodiments may safeguardan enterprise from carrying too much inventory and dynamically adjustingthe labor, tools, and work packages. For example, using the illustrativeembodiments, a lack of fuselages that affects all sub components in aripple effect may result in surplus labor and resources which can beimmediately, dynamically reallocated to other areas needing them, toavoid loss of time with respect to those areas. The illustrativeembodiments can assist an enterprise in coordinating with vendors tominimize ripple-effect disruptions to the vendors, disruptions that cancause cascading challenges inside the enterprise and externally withsuppliers.

The illustrative embodiments may concurrently manage groups of parts inmultiple manufacturing facilities. The illustrative embodiments may alsohelp prevent a cascade of shortages and overages for time, parts, andhuman resources. The illustrative embodiments may manage effectivities,which are the effects on planned updates, changes, and opportunities forthe manufacturing endeavor.

The following is an example of an effectivity. Aircraft may have tailmodel numbers, representing different models of aircraft. Say, forexample, tail models 301-330 for a block of planes with a particularspecification of parts may have an inconsistency. When the inconsistencyis detected, an update to manufacturing procedures and inventory may bedesirable. In addition to the update, the illustrative embodiments maytake into account the effectivity and retroactively update earlierblocks of tail models.

As described above, the illustrative embodiments allow for downstreammanagement of a manufacturing endeavor after a disruption of amanufacturing system. The illustrative embodiments may thus minimize thenegative effects on money, time, inventory, personnel, and vendorrelationships when a disruption event occurs.

FIG. 1 is a diagram illustrating a manufacturing materiel managementsystem, in accordance with an illustrative embodiment. Manufacturingmateriel management system 100 may be implemented using a combination ofa manufacturing assembly line and its supporting tools and machinery, aswell as a data processing system, such as data processing system 700 ofFIG. 7.

Manufacturing materiel management system 100 includes product inventorymonitor 102 including at least one processor having a memory and acommunications link. Manufacturing materiel management system 100 alsoincludes supplier dependency table 104, which may include at least oneof a minimum-maximum item matrix and an item supplier dependency matrix.

Manufacturing materiel management system 100 also includes manufacturingline item sensor network 106 coupled to product inventory monitor 102and configured to monitor in real-time inventory levels of a pluralityof components, sub-assemblies, and assemblies in the product inventoryused for a manufacturing line for manufacturing an object. Manufacturingmateriel management system 100 also includes disruption pattern detector108 in communication with manufacturing line item sensor network 106,and configured to detect normal and abnormal inventory turns, and togenerate therefrom normal and disruption patterns.

Manufacturing materiel management system 100 also includes resourceallocator 110 in communication with product inventory monitor 102,manufacturing line item sensor network 106, and disruption patterndetector 108. Resource allocator 110 may be configured to monitor thenormal and disruption patterns and to allocate resources to differentprojects when a disrupted pattern occurs.

Manufacturing materiel management system 100 also includes alertreporting system 112. Alert reporting system 112 may be used to issuealerts to personnel or to other aspects of manufacturing materielmanagement system 100.

These illustrative embodiments may be varied. For example, in additionto manufacturing line item sensor network 106, manufacturing materielmanagement system 100 may receive human triggers 114 as part of theinput received into any of product inventory monitor 102, supplierdependency table 104, disruption pattern detector 108, resourceallocator 110, or alert reporting system 112.

The effect of manufacturing materiel management system 100 may be animproved manufacturing system which more efficiently performsmanufacturing of physical objects. For example, manufacturing materielmanagement system 100 may provide for improved supplier demand guidance116. Manufacturing materiel management system 100 may also create ororganize an organically responsive supply chain 118 which is resistantto disruption events.

Thus, an effect of manufacturing materiel management system 100 may beto more efficiently manufacture multiple aircraft in the face of adisruption event, including a major disruption event. Another effect ofmanufacturing materiel management system 100 may be to more efficientlyorder movement of the physical location of parts used in themanufacturing endeavor. Another effect of manufacturing materielmanagement system 100 may be the reallocation of human resources in theface of a disruption event, such as to training, maintenance of existingaircraft instead of manufacture, transfer to other facilities, or otheradjustments. Many other variations are possible. Thus, the illustrativeembodiments are not necessarily limited by the examples provided above.

FIG. 2 is a diagram illustrating an operation of a disruptioncontroller, in accordance with an illustrative embodiment. An example oflearning event disruption controller 200 may be manufacturing materielmanagement system 100 of FIG. 1. Learning event disruption controller200 may be implemented using a data processing system, such as dataprocessing system 700 of FIG. 7.

Learning event disruption controller 200 may receive input from manydifferent sensors and/or human input. For example, learning eventdisruption controller 200 may use factory inventory level sensors 202,supplier level sensors 204, disruption pattern detector 206, demandsensors 208, user input 210, and other sources of input. Other sourcesof input may include disruption pattern library and algorithms 230,supplier dependency tables 232, and local inventory 234.

In use, learning event disruption controller 200 may read factoryinventory level sensors (operation 212), read supplier level sensors(operation 214), receive input on demand (operation 216), monitorservice alerts (operation 218), and receive user input (operation 220).Monitoring service alerts 218 may include monitoring manufacturing ratechange 221, emergency alerts 222, air deliveries 224, rail services 226,and personnel availability 228. Learning event disruption controller 200may also receive user input 220, read factory inventory level sensors212, read supplier level sensor 214, and receive input on demand 216.

All of the above input is then aggregated as sensor input and thencompared against known disruption patterns (operation 236). Adetermination is them made if a disruption has occurred (operation 238).In the case of a positive determination, learning event disruptioncontroller 200 assesses the extent of the disruption (operation 240). Inthe case of a negative determination, or if no disruption has occurred,learning event disruption controller 200 may review factory demandagainst supply and reallocate factory resources accordingly (operation242). As part of this operation, learning event disruption controller200 may receive additional input from manufacturing work flow system244.

Thereafter, a determination is made whether supplier levels areacceptable (operation 246). In the case of a positive determination,learning event disruption controller 200 may order the standardinventory quantities that had been originally planned (operation 248).In the case of a negative determination, learning event disruptioncontroller 200 may notify affected suppliers of the disruption and itsexpected duration (operation 250). Learning event disruption controller200 may also adjust supplier demand level quantities (operation 252).

Next, whether supplier levels were acceptable or not under operation246, learning event disruption controller 200 may provide prioritizedsupplier orders in the context of disruption events (operation 254).These orders may be fed back into demand sensors 208, and thus theprocess may continually operate until monitoring is no longer desired.Otherwise, the method may terminate thereafter.

The illustrative embodiments described with respect to FIG. 2 representonly an example. The processes and devices described with respect toFIG. 2 may be varied, and thus do not necessarily limit the otherillustrative embodiments described herein.

FIG. 3 is a diagram illustrating an example of a production line, inaccordance with an illustrative embodiment. Manufacturing environment300 is an example of an environment which may be improved by theillustrative embodiments described with respect to FIG. 1, FIG. 2, andFIG. 1 through FIG. 6. Specifically, manufacturing environment 300 maybe an aircraft manufacturing environment.

Manufacturing environment 300 may include production line 302, which isa production line of multiple aircraft. As shown in FIG. 3, on days oneand two fuselages are provided as expected, as shown in area 304.However, also shown in area 304, on day three fuselages are notprovided, representing a major disruption event. As a result, on daysfour, five, and six a fuselage supply chain disruption occurs, as shownin area 306, and as a result factory pull of parts 308 is alsodisrupted.

A manufacturing material management system, such as learning eventdisruption controller 200 of FIG. 2, may be used to reallocate labor andother resources in real time, as shown in area 310. As used herein “realtime” action means taking action immediately after an event or an ordersuch that reactions to an event take place nearly immediately after theevent.

The illustrative embodiments described with respect to FIG. 3 representonly an example. The processes and devices described with respect toFIG. 3 may be varied, and thus do not necessarily limit the otherillustrative embodiments described herein.

FIG. 4 is a block diagram illustrating a manufacturing materielmanagement system, in accordance with an illustrative embodiment.Manufacturing materiel management system 400 is another variation ofmanufacturing materiel management system 100 of FIG. 1 and learningevent disruption controller 200 of FIG. 2. Manufacturing materielmanagement system 400 may be used to manage manufacturing environment300 of FIG. 3.

Manufacturing materiel management system 400 includes product inventorymonitor 402, which includes at least one processor 404 having memory 406and communications link 408, as well as at least one of aminimum-maximum item matrix 410 and an item supplier dependency matrix412. These matrices may be implemented as databases.

Manufacturing materiel management system 400 also includes manufacturingline item sensor network 414 coupled to product inventory monitor 402.Manufacturing line item sensor network 414 may be configured to monitorin real-time inventory levels of a plurality of components 416,sub-assemblies 418, and assemblies 420 in the product inventory used fora manufacturing line for manufacturing object 422. As used herein,components are parts used to create a greater whole, such as object 422,which may be an aircraft for example. A sub-assembly as defined hereinas a collection of components, but which itself part of a greater whole,particularly assemblies 420. As used herein an assembly is a collectionof sub-assemblies or components that forms a significant part of anobject, which may be an aircraft for example.

Manufacturing materiel management system 400 may also include disruptionpattern detector 424. Disruption pattern detector 424 may be incommunication with manufacturing line item sensor network 414.Disruption pattern detector 424 may be configured to detect normal andabnormal inventory turns, and to generate therefrom normal patterns 426and disruption patterns 428.

Manufacturing materiel management system 400 may also include resourceallocator 430. Resource allocator 430 may be in communication withproduct inventory monitor 402, manufacturing line item sensor network414, and disruption pattern detector 424. Resource allocator 430 may beconfigured to monitor normal patterns 426 and disruption patterns 428and to allocate resources to different projects when a disrupted patternoccurs.

Manufacturing materiel management system 400 may be varied. For example,manufacturing materiel management system 400 may further include a lineresource plan allocation parameter configured to allocate resources fromthe manufacturing line when the disrupted pattern occurs. In anotherillustrative embodiment, for manufacturing materiel management system400 the resource allocator is further configured with a prioritydisruption parameter that defines, after the disrupted pattern occursand based on a type of the disrupted pattern, an adjustedminimum-maximum item matrix and an adjustment alert.

In yet another illustrative embodiment, the object comprises acommercial aircraft and the manufacturing line comprises an assemblyline for manufacturing the commercial aircraft. In this case, thedisruption event comprises a loss caused by a third party. Specifically,the loss may be loss of at least one of a major assembly, asub-assembly, and a component to be used in the manufacturing line. Inthis case, the resource allocator is configured to allocate resourcesthat would work on the at least one of the major assembly, thesub-assembly, and the component to at least one of: other sections ofthe manufacturing line and tasks other than the manufacturing line. Theresources may be selected from the group consisting of: personnel,machines, tools, parts, assemblies, monuments, power, and raw resources.

The illustrative embodiments described with respect to FIG. 4 representonly an example. The processes and devices described with respect toFIG. 4 may be varied, and thus do not necessarily limit the otherillustrative embodiments described herein.

FIG. 5 is a block diagram illustrating another manufacturing materielmanagement system, in accordance with an illustrative embodiment.

Manufacturing materiel management system 500 is another variation ofmanufacturing materiel management system 500 of FIG. 5, manufacturingmateriel management system 100 of FIG. 1 and learning event disruptioncontroller 200 of FIG. 2. Manufacturing materiel management system 400of FIG. 4 may be used to manage manufacturing environment 300 of FIG. 3.

Manufacturing materiel management system 500 may include manufacturingassembly line 502, including equipment 504 usable to manufacture object506 comprising plurality of parts 508, including part 510. Manufacturingmateriel management system 500 also includes computer 512 includingprocessor 514, input device 516, and non-transitory computer readablemedium 518 in communication with processor 514. Non-transitory computerreadable medium 518 may store computer usable program code 520executable by processor 514 to perform functions.

These functions include monitoring input device 516 for input thatindicates a disruption event, defined as an event in which manufactureof object 506 is disrupted as a result of loss of a resource or thepart. These functions also include, responsive to receiving the input,calculate another project which may continue. These functions alsoinclude, responsive to receiving the input, calculate remainingresources which may be allocated to the another project. These functionsalso include generating a resource re-allocation plan which defines howremaining resources are to be re-allocated to the another project.

Manufacturing materiel management system 500 also includes communicationsystem 522. Communication system 522 is in communication with computer512 and is configured to communicate the re-allocation plan to a managerof manufacturing assembly line 502.

This illustrative embodiment may be varied. For example, computer usableprogram code 520 may use a contextual awareness to generate the resourcere-allocation plan. The contextual awareness may be input to computer512 selected from the group consisting of: minimum and maximum supplychain values for the plurality of points, a description of anenvironmental event that impacts the manufacturing assembly line, anitem supplier dependency matrix that indicates dependencies betweensuppliers for different ones of the plurality of parts, and a durationof the event.

In another illustrative embodiment, manufacturing materiel managementsystem 500 may also include an alert system configured to present analert when the disruption occurs in any of the following: an externalsupply chain that is external to the manufacturing line, human resourcelimits (including personnel challenges such as employee strike or otherdisruptive events involving personnel), or other resource limits(including but not limited to electrical power outages, fuel shortages,material shortages, component shortages, and the like). In anotherillustrative embodiment, the another project may be manufacturing adifferent on the manufacturing assembly line. In still anotherillustrative embodiment, the another project comprises using themanufacturing assembly line to perform maintenance of an existingobject. In yet another illustrative embodiment, the another project maybe ceasing or reducing operation of the manufacturing assembly line andtransferring the remaining resources to a different manufacturingfacility at a different geographical location. In another illustrativeembodiment, the another projects may be initiating training orretraining of personnel who work on the manufacturing assembly line.

As used herein, disrupted is defined as use of the manufacturingassembly line being stopped or slowed. Disrupted also contemplates aforced re-arrangement of components, sub-assemblies, or assemblies onmanufacturing assembly line 502. As used herein, the part may be anassembly of sub-components.

In another illustrative embodiment, the input may be sensor output froma sensor disposed to monitor the manufacturing assembly line. However,the input may be at least one of user input and data received from athird party. In still an alternative illustrative embodiment, thecomputer usable program code is configured to be executable to performmachine learning to analyze disruption patterns and outcomes.

In another illustrative embodiment, communication system 522 may beconfigured to notify, responsive to receiving the input, a third partyvendor of the event. In this case, communication system 522 may befurther configured to direct, as part of the re-allocation plan, thethird party vendor to change production of the part or ofsub-components. Still further, the third party vendor may be directed toperform an action with respect to the part or the sub-components, theaction selected from the group consisting of: increasing production,decreasing production, stopping production, and starting production of adifferent part or sub-component.

The illustrative embodiments described with respect to FIG. 5 representonly an example. The processes and devices described with respect toFIG. 5 may be varied, and thus do not necessarily limit the otherillustrative embodiments described herein.

FIG. 6 is a flowchart of a method for manufacturing, in accordance withan illustrative embodiment. Method 600 may be implemented bymanufacturing materiel management system 100 of FIG. 1, learning eventdisruption controller 200 of FIG. 2, manufacturing materiel managementsystem 400 of FIG. 4, and manufacturing materiel management system 500of FIG. 5. Method 600 may be used to manage manufacturing environment300 of FIG. 3. Method 600 may be implemented by a data processingsystem, such as data processing system 700 of FIG. 7.

Method 600 may begin by operating a manufacturing assembly line,including using equipment to manufacture an object comprising aplurality of parts, including a part (operation 602). Next, method 600may include monitoring, by a computer, an input device in communicationwith the computer for input that indicates a disruption event defined asan event in which manufacture of the object is disrupted as a result ofloss of a resource or the part (operation 604).

Method 600 also includes, responsive to receiving the input,calculating, by the computer, another project which may continue(operation 606). Method 600 also includes, responsive to receiving theinput, calculating, by the computer, remaining resources which may beallocated to the another project (608).

Method 600 also includes generating, by the computer, a resourcere-allocation plan which defines how remaining resources are to bere-allocated to the another project (operation 610). Method 600 alsoincludes communicating, using a communication system connected to thecomputer, the re-allocation plan to a manager of the manufacturingassembly line (operation 612). The method may terminate thereafter.

The illustrative embodiments described with respect to FIG. 6 representonly an example. The processes and devices described with respect toFIG. 6 may be varied, and thus do not necessarily limit the otherillustrative embodiments described herein.

Turning now to FIG. 7, an illustration of a data processing system isdepicted in accordance with an illustrative embodiment. Data processingsystem 700 in FIG. 7 is an example of a data processing system that maybe used to implement the illustrative embodiments, such as themanufacturing materiel management systems described with respect to FIG.1 through FIG. 6. In this illustrative example, data processing system700 includes communications fabric 702, which provides communicationsbetween processor unit 704, memory 706, persistent storage 708,communications unit 710, input/output (I/O) unit 712, and display 1014.

Processor unit 704 serves to execute instructions for software that maybe loaded into memory 706. This software may be an associative memory,content addressable memory, or software for implementing the processesdescribed elsewhere herein. Processor unit 704 may be a number ofprocessors, a multiprocessor core, or some other type of processor,depending on the particular implementation. A number, as used hereinwith reference to an item, means one or more items. Further, processorunit 704 may be implemented using a number of heterogeneous processorsystems in which a main processor is present with secondary processorson a single chip. As another illustrative example, processor unit 704may be a symmetric multiprocessor system containing multiple processorsof the same type.

Memory 706 and persistent storage 708 are examples of storage devices716. A storage device is any piece of hardware that is capable ofstoring information, such as, for example, without limitation, data,program code in functional form, and/or other suitable informationeither on a temporary basis and/or a permanent basis. Storage devices716 may also be referred to as computer readable storage devices inthese examples. Memory 706, in these examples, may be, for example, arandom access memory or any other suitable volatile or non-volatilestorage device. Persistent storage 708 may take various forms, dependingon the particular implementation.

For example, persistent storage 708 may contain one or more componentsor devices. For example, persistent storage 708 may be a hard drive, aflash memory, a rewritable optical disk, a rewritable magnetic tape, orsome combination of the above. The media used by persistent storage 708also may be removable. For example, a removable hard drive may be usedfor persistent storage 708.

Communications unit 710, in these examples, provides for communicationswith other data processing systems or devices. In these examples,communications unit 710 is a network interface card. Communications unit710 may provide communications through the use of either or bothphysical and wireless communications links.

Input/output (I/O) unit 712 allows for input and output of data withother devices that may be connected to data processing system 700. Forexample, input/output (I/O) unit 712 may provide a connection for userinput through a keyboard, a mouse, and/or some other suitable inputdevice. Further, input/output (I/O) unit 712 may send output to aprinter. Display 714 provides a mechanism to display information to auser.

Instructions for the operating system, applications, and/or programs maybe located in storage devices 716, which are in communication withprocessor unit 704 through communications fabric 702. In theseillustrative examples, the instructions are in a functional form onpersistent storage 708. These instructions may be loaded into memory 706for execution by processor unit 704. The processes of the differentembodiments may be performed by processor unit 704 using computerimplemented instructions, which may be located in a memory, such asmemory 706.

These instructions are referred to as program code, computer usableprogram code, or computer readable program code that may be read andexecuted by a processor in processor unit 704. The program code in thedifferent embodiments may be embodied on different physical or computerreadable storage media, such as memory 706 or persistent storage 708.

Program code 718 is located in a functional form on computer readablemedia 720 that is selectively removable and may be loaded onto ortransferred to data processing system 700 for execution by processorunit 704. Program code 718 and computer readable media 720 form computerprogram product 722 in these examples. In one example, computer readablemedia 720 may be computer readable storage media 724 or computerreadable signal media 726. Computer readable storage media 724 mayinclude, for example, an optical or magnetic disk that is inserted orplaced into a drive or other device that is part of persistent storage708 for transfer onto a storage device, such as a hard drive, that ispart of persistent storage 708. Computer readable storage media 724 alsomay take the form of a persistent storage, such as a hard drive, a thumbdrive, or a flash memory, that is connected to data processing system700. In some instances, computer readable storage media 724 may not beremovable from data processing system 700.

Alternatively, program code 718 may be transferred to data processingsystem 700 using computer readable signal media 726. Computer readablesignal media 726 may be, for example, a propagated data signalcontaining program code 718. For example, computer readable signal media726 may be an electromagnetic signal, an optical signal, and/or anyother suitable type of signal. These signals may be transmitted overcommunications links, such as wireless communications links, opticalfiber cable, coaxial cable, a wire, and/or any other suitable type ofcommunications link. In other words, the communications link and/or theconnection may be physical or wireless in the illustrative examples.

In some illustrative embodiments, program code 718 may be downloadedover a network to persistent storage 708 from another device or dataprocessing system through computer readable signal media 726 for usewithin data processing system 700. For instance, program code stored ina computer readable storage medium in a server data processing systemmay be downloaded over a network from the server to data processingsystem 700. The data processing system providing program code 718 may bea server computer, a client computer, or some other device capable ofstoring and transmitting program code 718.

The different components illustrated for data processing system 700 arenot meant to provide architectural limitations to the manner in whichdifferent embodiments may be implemented. The different illustrativeembodiments may be implemented in a data processing system includingcomponents in addition to or in place of those illustrated for dataprocessing system 700. Other components shown in FIG. 7 can be variedfrom the illustrative examples shown. The different embodiments may beimplemented using any hardware device or system capable of runningprogram code. As one example, the data processing system may includeorganic components integrated with inorganic components and/or may becomprised entirely of organic components excluding a human being. Forexample, a storage device may be comprised of an organic semiconductor.

In another illustrative example, processor unit 704 may take the form ofa hardware unit that has circuits that are manufactured or configuredfor a particular use. This type of hardware may perform operationswithout needing program code to be loaded into a memory from a storagedevice to be configured to perform the operations.

For example, when processor unit 704 takes the form of a hardware unit,processor unit 704 may be a circuit system, an application specificintegrated circuit (ASIC), a programmable logic device, or some othersuitable type of hardware configured to perform a number of operations.With a programmable logic device, the device is configured to performthe number of operations. The device may be reconfigured at a later timeor may be permanently configured to perform the number of operations.Examples of programmable logic devices include, for example, aprogrammable logic array, programmable array logic, a field programmablelogic array, a field programmable gate array, and other suitablehardware devices. With this type of implementation, program code 718 maybe omitted because the processes for the different embodiments areimplemented in a hardware unit.

In still another illustrative example, processor unit 704 may beimplemented using a combination of processors found in computers andhardware units. Processor unit 704 may have a number of hardware unitsand a number of processors that are configured to run program code 718.With this depicted example, some of the processes may be implemented inthe number of hardware units, while other processes may be implementedin the number of processors.

As another example, a storage device in data processing system 700 isany hardware apparatus that may store data. Memory 706, persistentstorage 708, and computer readable media 720 are examples of storagedevices in a tangible form.

In another example, a bus system may be used to implement communicationsfabric 702 and may be comprised of one or more buses, such as a systembus or an input/output bus. Of course, the bus system may be implementedusing any suitable type of architecture that provides for a transfer ofdata between different components or devices attached to the bus system.Additionally, a communications unit may include one or more devices usedto transmit and receive data, such as a modem or a network adapter.Further, a memory may be, for example, memory 706, or a cache, such asfound in an interface and memory controller hub that may be present incommunications fabric 702.

The different illustrative embodiments can take the form of an entirelyhardware embodiment, an entirely software embodiment, or an embodimentcontaining both hardware and software elements. Some embodiments areimplemented in software, which includes but is not limited to forms suchas, for example, firmware, resident software, and microcode.

Furthermore, the different embodiments can take the form of a computerprogram product accessible from a computer usable or computer readablemedium providing program code for use by or in connection with acomputer or any device or system that executes instructions. For thepurposes of this disclosure, a computer usable or computer readablemedium can generally be any tangible apparatus that can contain, store,communicate, propagate, or transport the program for use by or inconnection with the instruction execution system, apparatus, or device.

The computer usable or computer readable medium can be, for example,without limitation an electronic, magnetic, optical, electromagnetic,infrared, or semiconductor system, or a propagation medium. Non-limitingexamples of a computer readable medium include a semiconductor or solidstate memory, magnetic tape, a removable computer diskette, a randomaccess memory (RAM), a read-only memory (ROM), a rigid magnetic disk,and an optical disk. Optical disks may include compact disk-read onlymemory (CD-ROM), compact disk-read/write (CD-R/W), and DVD.

Further, a computer usable or computer readable medium may contain orstore a computer readable or computer usable program code such that whenthe computer readable or computer usable program code is executed on acomputer, the execution of this computer readable or computer usableprogram code causes the computer to transmit another computer readableor computer usable program code over a communications link. Thiscommunications link may use a medium that is, for example withoutlimitation, physical or wireless.

A data processing system suitable for storing and/or executing computerreadable or computer usable program code will include one or moreprocessors coupled directly or indirectly to memory elements through acommunications fabric, such as a system bus. The memory elements mayinclude local memory employed during actual execution of the programcode, bulk storage, and cache memories which provide temporary storageof at least some computer readable or computer usable program code toreduce the number of times code may be retrieved from bulk storageduring execution of the code.

Input/output or I/O devices can be coupled to the system either directlyor through intervening I/O controllers. These devices may include, forexample, without limitation, keyboards, touch screen displays, andpointing devices. Different communications adapters may also be coupledto the system to enable the data processing system to become coupled toother data processing systems or remote printers or storage devicesthrough intervening private or public networks. Non-limiting examples ofmodems and network adapters are just a few of the currently availabletypes of communications adapters. The description of the differentillustrative embodiments has been presented for purposes of illustrationand description, and is not intended to be exhaustive or limited to theembodiments in the form disclosed. Many modifications and variationswill be apparent to those of ordinary skill in the art. Further,different illustrative embodiments may provide different features ascompared to other illustrative embodiments. The embodiment orembodiments selected are chosen and described in order to best explainthe principles of the embodiments, the practical application, and toenable others of ordinary skill in the art to understand the disclosurefor various embodiments with various modifications as are suited to theparticular use contemplated.

What is claimed is:
 1. A manufacturing materiel management system,comprising: a product inventory monitor including at least one processorhaving a memory and a communications link, and at least one of aminimum-maximum item matrix and an item supplier dependency matrix; amanufacturing line item sensor network coupled to the product inventorymonitor and configured to monitor in real-time inventory levels of aplurality of components, sub-assemblies, and assemblies in the productinventory used for a manufacturing line for manufacturing an object; adisruption pattern detector in communication with the manufacturing lineitem sensor network, and configured to detect normal and abnormalinventory turns, and to generate therefrom normal and disruptionpatterns; and a resource allocator in communication with the productinventory monitor, the manufacturing line item sensor network, and thedisruption pattern detector, and configured to monitor the normal anddisruption patterns and to allocate resources to different projects whena disrupted pattern occurs.
 2. The manufacturing materiel managementsystem of claim 1, further comprising: a line resource plan allocationparameter configured to allocate resources from the manufacturing linewhen the disrupted pattern occurs.
 3. The manufacturing materielmanagement system of claim 1, wherein the resource allocator is furtherconfigured with a priority disruption parameter that defines, after thedisrupted pattern occurs and based on a type of the disrupted pattern,an adjusted minimum-maximum item matrix and an adjustment alert.
 4. Themanufacturing materiel management system of claim 1, wherein the objectcomprises a commercial aircraft and the manufacturing line comprises anassembly line for manufacturing the commercial aircraft.
 5. Themanufacturing materiel management system of claim 4, wherein thedisruption pattern detector is further configured to detect a disruptionevent comprising a loss caused by a third party.
 6. The manufacturingmateriel management system of claim 5, wherein the loss comprises lossof at least one of a major assembly, a sub-assembly, and a component tobe used in the manufacturing line.
 7. The manufacturing materielmanagement system of claim 6, wherein the resource allocator isconfigured to allocate resources that would work on the at least one ofthe major assembly, the sub-assembly, and the component to at least oneof: other sections of the manufacturing line and tasks other than themanufacturing line.
 8. The manufacturing materiel management system ofclaim 7, wherein the resources are selected from the group consistingof: personnel, machines, tools, parts, assemblies, monuments, power, andraw resources.
 9. A manufacturing materiel management system comprising:a manufacturing assembly line, including equipment usable to manufacturean object comprising a plurality of parts, including a part; a computercomprising a processor, an input device, and a non-transitory computerreadable medium in communication with the processor, the non-transitorycomputer readable medium storing computer usable program code executableby the processor to: monitor the input device for input that indicates adisruption event defined as an event in which manufacture of the objectis disrupted as a result of loss of a resource or the part, or ashortage of human resources; responsive to receiving the input,calculate another project which may continue; responsive to receivingthe input, calculate remaining resources which may be allocated to theanother project; and generate a resource re-allocation plan whichdefines how remaining resources are to be re-allocated to the anotherproject; and a communication system in communication with the computerand configured to communicate the re-allocation plan to a manager of themanufacturing assembly line.
 10. The manufacturing materiel managementsystem of claim 9, wherein the computer usable program code uses acontextual awareness to generate the resource re-allocation plan. 11.The manufacturing materiel management system of claim 10, wherein thecontextual awareness comprises input to the computer selected from thegroup consisting of: minimum and maximum supply chain values for theplurality of parts, a description of an environmental event that impactsthe manufacturing assembly line, an item supplier dependency matrix thatindicates dependencies between suppliers for different ones of theplurality of parts, and a duration of the event.
 12. The manufacturingmateriel management system of claim 9 further comprising: an alertsystem configured to present an alert when any one of the followingevents occur: the disruption occurs in an external supply chain that isexternal to the manufacturing line; the disruption occurs due to a limitin human resources; and the disruption occurs due to a limit in aresource.
 13. The manufacturing materiel management system of claim 9,wherein the another project comprises manufacturing a different on themanufacturing assembly line.
 14. The manufacturing materiel managementsystem of claim 9, wherein the another project comprises using themanufacturing assembly line to perform maintenance of an existingobject.
 15. The manufacturing materiel management system of claim 9,wherein the another project comprises ceasing or reducing operation ofthe manufacturing assembly line and transferring the remaining resourcesto a different manufacturing facility at a different geographicallocation.
 16. The manufacturing materiel management system of claim 9,wherein the another projects comprises initiating training or retrainingof personnel who work on the manufacturing assembly line.
 17. Themanufacturing materiel management system of claim 9, wherein disruptedis defined as use of the manufacturing assembly line being stopped orslowed.
 18. The manufacturing materiel management system of claim 9,wherein the part is an assembly of sub-components.
 19. The manufacturingmateriel management system of claim 9, wherein the input comprisessensor output from a sensor disposed to monitor the manufacturingassembly line.
 20. The manufacturing materiel management system of claim9, wherein the input comprises at least one of user input and datareceived from a third party.
 21. The manufacturing materiel managementsystem of claim 9, wherein the computer usable program code isconfigured to be executable to perform machine learning to analyzedisruption patterns and outcomes.
 22. The manufacturing materielmanagement system of claim 9, wherein the communication system isconfigured to notify, responsive to receiving the input, a third partyvendor of the event.
 23. The manufacturing materiel management system ofclaim 22, wherein the communication system is further configured todirect, as part of the re-allocation plan, the third party vendor tochange production of the part or of sub-components.
 24. Themanufacturing materiel management system of claim 23, wherein the thirdparty vendor is directed to perform an action with respect to the partor the sub-components, the action selected from the group consisting of:increasing production, decreasing production, stopping production, andstarting production of a different part or sub-component.
 25. A methodof manufacturing, comprising: operating a manufacturing assembly line,including using equipment to manufacture an object comprising aplurality of parts, including a part; monitoring, by a computer, aninput device in communication with the computer for input that indicatesa disruption event defined as an event in which manufacture of theobject is disrupted as a result of loss of a resource or the part;responsive to receiving the input, calculating, by the computer, anotherproject which may continue; responsive to receiving the input,calculating, by the computer, remaining resources which may be allocatedto the another project; generating, by the computer, a resourcere-allocation plan which defines how remaining resources are to bere-allocated to the another project; and communicating, using acommunication system connected to the computer, the re-allocation planto a manager of the manufacturing assembly line.